Face Shield for Safety Helmet

ABSTRACT

A substantially clear cycle face shield adapted for use with a cycle helmet comprised of: a mesh face cover adapted to be secured to the cycle helmet, either temporarily or permanently, for protecting the user&#39;s face when bicycling, which is manufactured using a process having a bleed rate of no more than 0.1 centimeter and which is anthropometrically designed to conform to the face and head of a user. The cycle face shield can be rigid or flexible, flat or arcuate, and can cover just the face or extend downward to protect the throat and/or extend rearward along the sides of the helmet to protect the ears and neck.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority, in part, to U.S. ProvisionalApplication No. 60/952,756 filed Jul. 30, 2007.

FIELD OF INVENTION

This invention relates generally to the field of protective sportsequipment for a cycle rider, and specifically an accessory for a cyclehelmet to protect a rider's face from insects and debris.

BACKGROUND OF THE INVENTION

It is well known in the art for motorcyclists to use helmets with faceshields. Motorcycle helmets commonly include some sort of face shield toprotect motorcycle riders (i.e., an enclosed helmet, a full face guard,or a partial face guard). However, the use of helmets by cycle ridershas only relatively recently become common.

Cycle safety helmets are commonly molded with a hard plastic materialhaving an inner close fitting foamed polymer liner. In case of anaccident, the helmet is capable of withstanding the shock loads by thehard plastic shell of the helmet along with the resilience in the foamlining so that the force of the impact is distributed over a wider areato reduce the dangers of concussion and other head injuries. Indeed, thewearing of a regulation cycling-helmet of some type is now mandatory inmany states. Thus, cyclists are becoming more accustomed to the use ofhelmets.

However, cycle helmets do not typically include face shields. Moreover,purchasers of cycle helmets may vary in their preferences as to whetheror not they would like to wear a face shield.

It is thus desirable to have a face shield that is selectivelyattachable to a cycle helmet and which can be securely attached to ahelmet without remanufacturing or specialized tools or processes, andwhich is proportioned to be used on helmets of varying sizes and shapes.

It is further desirable to have a face shield which can beinexpensively, safely and reliably manufactured and that such method ofmanufacture result in a device which will not impact the user'speripheral vision.

It is also desirable to have a flexible face shield which can be adaptedto various size helmets and withstand the impact of the wind when acycle is in motion, which allows the passage of air through thestructure and which retains its shape and position under suchconditions.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a cycle face shield forselective attachment to a cycle helmet which allows air to pass throughthe shield without obstructing a cyclist's view or affecting thecyclist's peripheral vision.

It is further an object of this invention to provide a cycle helmet andface shield protection system comprising a cycle helmet and a mesh faceshield adapted for selective attachment to the helmet, using a method ofmanufacture which results in economic replication of a device withminimal “bleeding” of the molded material onto the viewable surface ofthe shield (“acceptable bleed rate”).

The invention can be adapted for varying size helmets, and for male,female and adult helmet proportions. It may also be constructed ofvarying sizes of mesh (weave density) to provide varying levels of airflow and protection from insect and debris.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a side view of a cyclist wearing one embodiment of a cyclehelmet with the cycle face shield.

FIG. 2 shows a side perspective view of one embodiment of the cycle faceshield secured to a helmet.

FIG. 3 shows a side perspective view of an alternate embodiment of thecycle face shield secured to a helmet.

FIG. 4 shows a side perspective view of an alternate embodiment of thecycle face shield with a black rubber border.

FIG. 5 shows a side perspective view of an alternate embodiment of thecycle face shield having ornamentation.

GLOSSARY

As used herein, the term “helmet” refers to any head covering worn by acyclist, regardless of the material, the extent of the head/facecovered, and whether it contains aerodynamic features.

As used herein, the term “mesh” means a material constructed of amaterial having the appearance of a net through which air can pass, butwhich impedes the passage of bugs and debris. As used herein, meshrefers to any netting, screen or mesh-like material having any weavedensity or proportion known in the art and typically associated withmesh. Mesh may be constructed from plastic, cloth, metal alloys,aluminum or any other material known in the art for forming mesh.

As used herein, the term “cycle” refers to a cycle or motorizedtransportation device for which a helmet is traditionally worn toprotect a rider. A cycle may include a cycle, a motor scooter, a motorcycle, a moped or any other motorized or non-motorized transportationdevice know in the art.

As used herein, the term “bleed rate” refers to excess plastic or othermaterial known in the art which leaches or escapes from a defined moldcavity during a manufacturing process. For example, a bleed rate mayrefer to plastic or rubber which leaches from a mold used to construct aframe or mesh, in particular the frame used to seal the aluminum fiberends. A bleed rate may refer to the rate at which a plastic, rubber,polyolefin elastomeric Thermoplastic Elastomer or any other materialknown in the art may leach or bleed from within the contours of a mold,and in particular, the rate at which an injection molded frameconstructed around a piece of die-cut mesh bleeds into the mesh,leaching from the frame mold.

As used herein, an “acceptable bleed rate” is less than o 1/16^(th) ofan inch to 0.1 cm or one square of mesh, depending upon the meshdensity.

As used herein, the term “face shield” refers to a mesh or functionallysimilar material adapted to shield the face of a cyclist from mesh anddebris.

As used herein, the term “adherent” means a means of affixing a faceshield to a cycle helmet and may include Velcro, adhesive, adhesivestrips, snaps, hooks, bolts, welding, heat sealing, single moldingdesign, contouring, suction, screws, specially constructed components tofit within corresponding apertures or any other means of attachmentknown in the art.

As used herein, the term “arcuate” means curved or contoured, forexample to complement the shape of a helmet or dimensions of a user'sface, or to overcome wind resistance.

As used herein, the term “anthropometrically” means in accordance withor taking into account human proportions (e.g., male, female, adult,child) in a design, particularly with respect to the proportions of theface and head.

As used herein, the term “non-visible surface” means the surface of aface shield which faces inwardly toward the user's face.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

For the purpose of promoting an understanding of the present invention,references are made in the text hereof to embodiments of a cycle faceshield, only some of which are depicted in the figures. It shouldnevertheless be understood that no limitations on the scope of theinvention are thereby intended. One of ordinary skill in the art willreadily appreciate that modifications such as the dimensions, size, andshape of the components, alternate but functionally similar materials(e.g., mesh) from which the cycle face shield is made, and the inclusionof additional elements are deemed readily apparent and obvious to one ofordinary skill in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the written description donot depart from the spirit and scope of the present invention. Some ofthese possible modifications are mentioned in the following description.Therefore, specific details disclosed herein are not to be interpretedas limiting, but rather as a basis for the claims and as arepresentative basis for teaching one of ordinary skill in the art toemploy the present invention in virtually any appropriately detailedapparatus or manner.

It should be understood that the drawings are not necessarily to scale,emphasis instead being placed upon illustrating the principles of theinvention. In addition, in the embodiments depicted herein, likereference numerals in the various drawings refer to identical or nearidentical structural elements. For example the face shield describedherein may be of varying shapes and proportions to accommodate varioussize users and helmets and levels of wind resistance, and to accommodateusers wearing glasses or other facial accessories.

Moreover, the term “substantially” or “approximately” as used herein maybe applied to modify any quantitative representation that couldpermissibly vary without resulting in a change in the basic function towhich it is related. For example, one embodiment of the cycle faceshield is disclosed herein as being oriented substantially parallel to acyclist's face when secured to a cycle helmet and worn. The cycle faceshield might permissibly be oriented substantially non-parallel to theuser's face when secured to a helmet and worn by the cyclist and stillbe within the scope of the invention if its functionality is in a nonparallel not materially altered.

Referring now to the drawings, FIG. 1 shows a side view of cyclist 50wearing one (1) embodiment of cycle helmet 55 with cycle face shield 100attached thereto. As can be appreciated, cycle helmet 55 is temporarilysecured to cyclist's 50 head 52 by chin strap 56, and cycle face shield100 is secured to the front of cycle helmet 55 to protect the face ofcyclist 50.

FIG. 2 shows a top perspective view of the embodiment of cycle faceshield 100 secured to cycle helmet 55 shown in FIG. 1. As can beappreciated, cycle face shield 100 is secured to forward portion 59 ofcycle helmet 55 to protect a cyclist's face (not shown). In theembodiment shown, cycle face shield 100 is made of a substantially rigidmesh 105 shaped by die-cutting or any other method, and may be a plasticor metal mesh sealed with a thermoplastic elastomeric rubber a to createframe 110 which seals the ends of the mesh. In the embodiment show, faceshield 100 is affixed to cycle helmet 55 by adherent 60, which in theembodiment shown is a set of complementary adhesive-backed Velro strips.In such an embodiment, cycle face shield 100 protects the cyclist'sforehead, eyes, ears cheeks, nose, and chin. However, it should beunderstood that alternate embodiments of cycle face shield 100 couldextend lower (See FIG. 3) to protect the cyclist's ears, neck and throatand/or outward to provide some protection to the cyclist's ears ofspeeds of between four and forty miles per hour.

In the embodiment shown adherent 60 are Velcro strips having a nonwater-soluble adhesive backing. In the embodiment shown, the Velcrostrips used as adherent 60 are approximately one to one inches wide by6-8 inches and of sufficient flexibility to accommodate varying sizes ofhelmets, and helmet contours, while providing a sufficient adhesivesurface to withstand winds of up to 40 mph on a bicycle helmet andsubstantially higher speed for motorcycles.

In various other embodiments, adherents may include adhesive strips,snaps, hooks, bolts, welding, heat sealing, single molding design,contouring, suction, screws, specially constructed components to fitwithin corresponding apertures or any other means of attachment known inthe art.

In the embodiment shown, face screen 100 is created by suspendingdie-cut mesh 105 in an injection mold, into which polyolefin elastomeric(Thermoplastic Elastomer) or any other material known in the art havingan acceptable bleed rate is injected to form frame 110 which seal themesh fiber ends of mesh 105 and prevents them from irritating a user'sface. The fibers of the mesh are vertically suspended within a mold, andcentered to minimize the bleed rate during the injection process, andminimize the movement of the fibers within the frame. The mesh ends aresealed and coated within the molded frame to prevent movement of thefibers and protect a users face from the ends of the fibers.

The cycle face shield is desirably formed of a single molding processhaving an acceptable bleed rate (i.e., the amount of plastic whichleaches or escapes from a defined mold cavity during the manufacturingprocess), e.g., of no more than 0.1 cm.

This embodiment of cycle face shield 100 is substantially flatvertically, but has in other embodiments could be sloped or have anarcuate curve. It should be understood that cycle face shield 100 can berigidly constructed and custom-curved for a specific make and/or modelof cycle helmet 55, or cycle face shield 100 can be somewhat flexible,allowing it to be bent horizontally vertically or horizontally for usewith a variety of cycle helmets 55, and for users having adult,juvenile, male or female anthropometric proportions. Further alternateembodiments of cycle face shield 100 can be more or less horizontallyarcuate along arrow A, be multi-faceted, or be substantially flat.

In the embodiment shown, cycle face shield 100 has tapered edges 69 aand 69 b, and flattened edge 71 to minimize wind resistance and conform.In the embodiment shown, edges 69 a and 69 b are tapered at anapproximate 12-20 degree angle. The embodiment of cycle face shield 100shown in FIG. 3 is secured to cycle helmet 55 by a Velcro™ strip 60,thus creating a selectively removable, attachment of cycle face shield100 to cycle helmet 55, whereby the face 100 can be disengaged byseparating the complementary Velcro strips.

FIG. 3 shows an alternate embodiment in which cycle face shield 100 ispermanently secured to cycle helmet 55 via apertures 55 a, 55 b and 55 ccreated during the molding process. Other embodiments may have varyingnumbers, shapes and sizes of apertures for affixation. Thus, it shouldbe understood that cycle face shield 100 can be secured to cycle helmet55 by any mechanism known and commonly used in the art, including butnot limited to snaps, an adhesive, a hook and latch mechanism, buttons,the use of one (1) or more hooks on either cycle helmet 55 or, cycleface shield 100 and corresponding apertures on the other, or a band thatencircles cycle helmet 55.

Furthermore, the mechanism by which cycle face shield 100 is secured tocycle helmet 55 should not be limited to any particular number ofattachment points. For example, the embodiment of cycle face shield 100shown in FIG. 2 is secured to cycle helmet 55 by four (4) Velcro™ strip60, but can be secured by any number of Velcro™ strip 60. It should alsobe understood that the same is true for the other attachment mechanisms,whether permanent or temporary.

The embodiment of cycle face shield 100 shown in FIGS. 1 through 2 ismade of a substantially clear and rigid or semi metal or plastic meshplastic which air allows air to pass through. This provides sufficientprotection against dirt, debris, and insects for the cyclist as well asnot obstructing the cyclist's view and permitting air flow. It alsoallows easy cleaning of cycle face shield 100. However, one of ordinaryskill in the art that other materials that provide similar advantagesand have similar characteristics can be used so long as the materialsare substantially clear to permit ease of viewing through cycle faceshield 100.

FIG. 4 shows a top perspective view of an alternate embodiment of cycleface shield 100 secured to cycle helmet 55. In the embodiment shown,cycle face shield 100 is aerodynamically shaped to minimize windresistance, being wider at the top and tapered on the sides. In otherembodiments, faces shield 100 may be of varying dimensions toaccommodate male, female, adult and juvenile uses and/or to provideadditional protection for the cyclist's neck. FIG. 4 shows tapered edges69 a and 69 b, and flattened edge 71 which is narrower than upper edge73 to minimize wind resistance and conform. In the embodiment shown,edges 69 a and 69 b are tapered at an approximate 12-20 degree angle.

In the embodiment shown in FIG. 4, cycle face shield 100 is made of adie cut me metallic mesh 105 which has been suspended in a plasticinjection mold into which plastic as been injected to seal the ends ofthe mesh and create a frame 110. In the embodiment shown, the acceptablebleed rate from the frame portion of the mold is no more than 0.1 cm.The aerodynamic design of the face shield allows the face shield 100 tohang vertically whether the cyclist is looking forward or downward. Sucha construction will also provide greater comfort for some users. In thisembodiment the mesh is clear in color, but in other embodiments the meshmay be of another color or may be constructed of aluminum, plastic,carbon fiber, fiber glass, polymer, resin, metal or any other substancecapable of being formed into a lightweight mesh which may be attached toa cycle helmet.

In still other alternate embodiments of cycle face shield 100, cycleface shield 100 can extend substantially around the sides of cyclehelmet 55 or even extend entirely around cycle helmet 55. Such analternate embodiment of cycle face shield 100 will provide additionalprotection to the cyclist's ears and/or back of the neck. Especially forthose embodiments of cycle face shield 100 using the flexible mesh shownin and described with respect to FIG. 3, such an embodiment will alsoprovide protection against insects.

While the cycle face shield has been shown and described with respect toseveral embodiments and uses in accordance with the present invention,it is to be understood that the same is not limited thereto, but issusceptible to numerous changes and modifications as known to a personof ordinary skill in the art, and it is intended that the presentinvention not be limited to the details shown and described herein, butrather cover all such changes and modifications obvious to one ofordinary skill in the art.

In the embodiment shown, face shield mesh 105 is constructed from acoated aluminum screen cloth known in the art as Goldstrand, but may beconstructed of any other material such as plastic, rubber, resin, metalalloys, fabric or other metals. For example, ingredients such aschromium, magnesium, and manganese may be added or used in anyproportion.

Various exemplary embodiments may have a frame constructed of a clear orvisually minimized frame 110, with approximate dimensions of one-fourthto one-eighth inch, sealing the edges of the mesh and one or more bondedlayers of mesh, Velcro™, labels or other layers of materials at the topand sealing or locking the mesh ends together for strength and toprevent the user's face from becoming scratched or irritated. A plastic,clear polymer or other material capable of molding and sealing may beused.

In various embodiments mesh screen 105 alternately colored aluminum meshfibers, created by painting or screening or by interweaving ofalternately colored fibers, for example to create a whimsical mask-likeeffect or holographic visual effect (not shown).

FIG. 5 shows an alternative embodiment which includes ornamentation 150consisting of painting, screening and/or imaging. Other ornamentationmay include holographic images, phosphorescent areas, sports logos,symbols, colors, objects, glow-in-the dark or glitter effect.Ornamentation may be achieved a screening process, painting, molding,machining or by affixing ornamentation with and adhesive

1. A cycle face shield comprising a mesh material adapted for selectiveattachment to a cycle helmet and allowing air to pass through saidwherein said mesh material is contoured and constructed from a processhaving an acceptable bleed rate so that the face shield does notinterfere with the peripheral vision of the user; a molded frame whichseals the ends of the mesh material; and an adherent.
 2. A cycle faceshield as in claim 1 wherein said adherent consists of correspondingadhesive packed Velcro strips which securely bind said molded frame tothe contours of a helmet.
 3. A cycle face shield as in claim 1 whereinsaid shield includes at least one indicia selected from a groupconsisting of a label, decorative coloration, a phosphorescent material,an image, a logo, a symbol, a glitter effect, or an object.
 4. A cycleface shield as in claim 1 wherein said shield is tapered andproportionate in size to said helmet and said user.
 5. A cycle faceshield as in claim 1 wherein said mesh is comprised of a materialselected from a group consisting of aluminum, plastic, carbon fiber,fiber glass, polymer resin, polyolefin elastomeric material, and metal.6. A cycle face shield as in claim 1 wherein said molded frame iscomprised of a material selected from a group consisting of aluminum,plastic, carbon fiber, fiber glass, polymer resin, polyolefinelastomeric material, and metal.
 7. A cycle helmet and face shieldprotection system comprising a mesh face shield; a molded frame; and anadherent.
 8. A cycle helmet protection system as in claim 7 wherein saidface shield is adapted for selective attachment along a forward portionof said helmet using a means of attachment selected from a groupconsisting of Velcro, adhesive, adhesive strips, snaps, hooks, bolts,welding, heat sealing, single molding design, contouring, suction,screws, specially constructed components to fit within correspondingapertures
 9. A cycle helmet protection system as in claim 7 wherein atleast a portion of said face shield is arcuate to conform to thecontours of a user's head.
 10. A cycle helmet protection system as inclaim 7 said face shield is anthropometrically designed so as not toaffect a user's peripheral vision.
 11. A cycle helmet protection systemas in claim 7 wherein said face shield utilizes adhesive backed Velcrostrips as a means for secure attachment of said face shield to saidhelmet.
 12. A method of manufacturing a cycle face shield comprisingcreating a anthropometrically proportioned die-cut mesh face screen;placing said die cut mesh face screen in an injection mold; injecting amolded substance in said injection mold to create a frame which framessaid die cut mesh face screen; and affixing an adherent to said faceshield to a cycle helmet using an adherent.
 13. The method of claim 12wherein said molded substance has an acceptable bleed rate.
 14. Themethod of claim 12 wherein said adherent comprised of a Velcro stripwhich adheres to a bike helmet and a Velcro strip which adheres to saidface shield.
 15. The method of claim 12 wherein said adherent is affixedto the non-visible upper surface of said face shield and said helmet.16. The method of claim 12 wherein said face shield is selectivelyattached to said cycle helmet.
 17. The method of claim 12 wherein saidface shield is permanently affixed to said cycle helmet.
 18. The methodof claim 12 wherein said face shield is anthropometrically proportionedso as not to interfere with the peripheral vision of a wearer.
 19. Acycle helmet shield device comprising; a face shield constructed ofsingly molding a frame around an anthropometrically proportioned pieceof mesh; a molded frame constructed from a process having an acceptablebleed rate so that the outer border of the mesh material does not impairthe vision of the user; and an adherent for attaching said face shieldto said helmet wherein said adherent is sufficiently flexible to conformto the contours of various helmets and of withstanding vibrations andmotions of a cycle.
 20. The cycle helmet shield system of claim 19wherein said face shield is tapered and anthropometrically proportionedso as not to impair the peripheral vision of a user during the act ofriding a cycle and which is tapered to remain in place when wind forceis encountered during cycling.